Chlorinated vinyl chloride resin compositions

ABSTRACT

CHOLRINATED VINYL CHLORIDE RESIN COMPOSITIONS COMPRISING CHLORINATED VINYL CHLORIDE RESINS OF AT LEAST 61% CHLORINE CONTENT MIXED WITH VINYL CHOLRIDE RESINS COMBINED WITH OR IN ALTERNATION WITH CHLORINATED VINYL CHLORIDE RESINS, OF LESS THAN 61% CHLORINE; AND TO WHICH MIXTURE, FOR OTHER EMBODIMENTS, RUBBERY BUTADIENE POLYMERS-VINYL COMPOUND INTERPOLYMERS MAY BE MIXED; AND METHODS OF PREPARING THE SAME.

Feb. 1, 1972 MICHIHIRO KAMEISHI 3,639,525

CHLORINATED VINYL CHLORIDE RESIN COMPOSITIONS Original Filed March 8, 1967 1 6| 62 63 64 65 66 67 CHLORINE WEIGHT,

I 575859&)

W mm2 g :66 3E;

FlG.l

ES 9 335 6&2 mm 9 O 7 6 5 4 3 ENGTH CLASH & BERGS SOFTENING TEMPERATURE IMPACT STR CHLORINE WEIGHT, 4

FIGZ

INVENI'OR MICHIH IRO KAMEISHI ATTORNEY United States Patent O U.S. Cl. 260-891 1 Claim ABSTRACT OF THE DISCLOSURE Chlorinated vinyl chloride resin compositions comprising chlorinated vinyl chloride resins of at least 61% chlorine content mixed with vinyl chloride resins combined with or in alternation with chlorinated vinyl chloride resins, of less than 61% chlorine; and to which mixture, for other embodiments, rubbery butadiene polymers-vinyl compound interpolymers may be mixed; and methods of preparing the same.

This application is a continuation of SN. 622,026, filed Mar. 8, 1967, now abandoned.

This invention relates to chlorinated vinyl chloride resin compositions. Its object is to create such compositions which are excellent in impact resistance, and have good processing properties.

Heretofore many methods are known that are useful in improving the productivity, impact strength, weathering resistance and other physical properties of the chlorinated vinyl chloride resins. In the representative methods, organic or polymeric plasticizers are added to the resins, or chlorinated vinyl chloride and other monomers copolymerisable therewith are copolymerized. All these methods are defective. For example, with regard to the intended product, when organic plasticizers (e.g., dioctyl phthalate, dibutylphthalate) are added, its Clash and Bergs softening temperature is substantially decreased, making the addition in large quantity impractical. Therefore, its melt flow index is barely improved. Moreover, this method noticeably deteriorates impact strength and other physical properties, and the plasticizer contained gets out of the reaction system.. When the polymeric plasticizers (for example, nitrile rubber) are added, generally, heat stability and Clash and Bergs softening temperature are substantially reduced, and the manufacturing cost is high. On the other hand, in producing the copolymers, the objective is hardly attainable because of the properties of the comonomers which are not all best suited to this purpose.

Free from such defects as evidenced in the usual arts, the present invention has introduced (1) mixtures of chlorinated vinyl chloride resins of not less than 61% (by weight; the same applies hereinafter) chlorine content with vinyl chloride resins and/or chlorinated vinyl chloride resins of less than 61% chlorine content, and (2) chlorinated vinyl chloride resin compositions made up by homogeneously mixing with these mixtures rubbery butadiene polymers-viny1 compound interpolymers. Details follow:-

First, the chlorinated vinyl chloride resins of not less than 61% chlorine content are formed by chlorinating the vinyl chloride resins. The said vinyl chloride resins are the homopolymer of vinyl chloride or its copolymers with comonomers polymerizable therewith with the former predominating the latter in amount. Such comono mers include vinyl acetate, methyl methacrylate, styrene, vinyl ether, etc. The vinyl chloride resins with less than 3000 polymerization degree are adaptable, 2000-300 ice being especially suitable. Any of the following methods is acceptable for their chlorination, the gas phase method, the liquid phase method, or the suspension method, or other similar methods.

The vinyl chloride resin and/or the chlorinated vinyl chloride resins of less than 61% chlorine content are of 800 to 200 polymerization degree as measured in accordance with I IS (Japanese Industrial Standard)K672l. The said vinyl chloride resins are the homopolymer of vinyl chloride or its copolymers with comonomers polymerizable therewith, with the former predominating the latter in amount. Such comonomers include vinyl acetate, methyl methacrylate, styrene, vinyl ether, etc. The chlorinated vinyl chloride resins of less than 61% chlorine content are formed by chlorinating the said vinyl chloride resins. The methods of chlorination are the same in case of chlorinating the chlorinated vinyl chloride resin of not less than 61% chlorine content.

The interpolymers include, for example, the three component system tripolymers of styrene-acrylonitrile-butadiene or mixtures containing these three components (abbreviated hereinafter as ABS), or the three component system tripolymers of styrene-methyl methacrylate-butadiene (abbreviated as MBS) or the four component system polymers of styrene-acrylonitrile-methyl methacrylate-butadiene or mixtures containing these four components in predominant amounts (hereinafter abbreviated as MABS). No special limitations are placed on the choice among ABS, MBS and MABS, being the rubbery butadiene polymers-vinyl compounds interpolymers. However, in the case of ABS, desirable are the compositions falling Within the range of approximately 45-25:25-20:30-50 in the molecular ratio of styrene:acrylonitrilezbutadiene.

In the case of M38, approximately 40-25:35-20: 30-50 in the molecular ratio of styrenezmethyl methacrylatezbutadiene are desirable.

In the case of MABS, compositions falling within the range of approximately 45-20225-l0130-l0230-50 in the molecular ratio of styrene:acrylonitrile:methyl methacrylatezbutadiene are desirable.

The intended products are obtained by homogeneously mixing in arbitrary proportions the vinyl chloride resins and/or the chlorinated vinyl chloride resins of less than 61% chlorine content with the chlorinated vinyl chloride resins of not less than 61% chlorine content. The proportions of the chlorinated vinyl chloride resins being 95 -50% and the vinyl chloride resins being the balance are especially suitable to this purpose.

On the other hand, the mixing proportion of the aforementioned vinyl chloride resin and/or the chlorinated vinyl chloride resins of less than 61% chlorine content, the chlorinated Vinyl chloride resins of not less than 61% chlorine content, and the interpolymers, may be arbitrarily chosen. However, desirable are the chlorinated vinyl chloride resins of not less than 61% chlorine content -50%, the vinyl chloride resins and/ or the chlorinated vinyl chloride resins of less than 61% chlorine content 5-47%, and the afore-mentioned reinforcing modifier 3-30%. Ordinary methods of mixing are applicable. For example, mixing may be done homogeneously into gelation by the use of the Banbury mixer or other blenders. From these compositions, products are easily obtained by ordinary methods, for example, through extrusion, calendering and blow molding.

Below are shown the merits or eifects of this invention:

1) In the intended compositions, the higher the mixing proportion of the chlorinated vinyl chloride resins, the flow temperature greatly decreases, despite the decrease in Clash and Bergs softening temperature is small in comparison with the chlorinated vinyl chloride homopolymers.

On the other hand, the flow temperatures of the intended compositions are always higher than those of the vinyl chloride resins, but the differences between them are small. These two reasons are responsible for the characteristic of the improvements in the processings mentioned above. This characteristic is always obtainable irrespective of the mixing proportion of the chlorinated 'vinyl chloride resins tie the vinyl chloride resins and/ or the chlorinated vinyl chloride resins of less than 61% chlorine content. However, notable value in industrial applications is achieved when the mixing proportion of the chlorinated vinyl chloride resins falls within the range of 90-50%.

These relationships mentioned above are represented in detail in FIG. 1. The real line shows the relationship be tween the chlorine content (weight percent) of the chlorinated vinyl chloride homopolymers and the initial flow temperature; the broken line 1 shows the relationship between the chlorine content and the initial flow temperature in the mixture composition system of the chlorinated vinyl chloride polymers (chlorine content 64%) and vinyl chloride polymers; the broken line 2 similarly shows the relationship between the chlorine content and the initial flow temperature in the mixture composition system of the chlorinated vinyl chloride polymers (chlorine content 66%) and vinyl chloride polymers; and the broken line 3 shows the relationship between the chlorine content and v the initial flow temperature in the mixture composition sys- In FIG. 2, the relationships between the chlorine content, the impact strength and the Clash and Bergs softening temperature in these systems are indicated.

As for the mixing proportion of the reinforcing modifier, the greater this proportion, the impact strength is improved. However, mixing of 3-30% is suitable in view of the use to which the products are put, as well as the value in industrial applications.

(3) The intended compositions in which the chlorinated vinyl chloride resins of high chlorine contents and the counterpart vinyl chloride resins and/or the chlorinated vinyl chloride resins of less than 61% chlorine contents are of low average polymerization degrees (T =200-800) or in which the reinforcing modifier is added to the aforementioned resins, show 'a notable improvement effect, especially in the melt flow index. Although it is possible to serve the end of this invention with compositions consisting of chlorinated vinyl chloride resins of low chlorine contents and vinyl chloride resins of high average polymerization degrees and/or the chlorinated vinyl chloride resins of less than 61% chlorine contents, or with these compositions mixed with the reinforcing modifiers, improvement in the melt flow index is not so notable as in the former ones.

This invention is exemplified in the following examples.

EXAMPLE 1 The mixture compositions of the chlorinated vinyl chloride polymers of various polymerization degrees and chlorine contents and the vinyl chloride polymers of various polymerization degrees were examined in many 'ways. Several examples are listed in the following table.

The following compositions were subjected to calendering, and the fiow condition of the bank was observed (the calender roll used was the 4-roll inverted L calender with the roll diameter 8 inch, the roll temperature 180- 185 Q).

Chlorinated vinyl chloride resin 01 content Clash and Condition the Bergs of the composition softening Parts Vinyl chloride resin Parts bank (percent) temperature Chlorinated 64%; 1 =1,000 100 64. 0 99 Chlorinated 66%; T =1,000 63.7 94 Chlorinated 63%; 2 1,000 100 63. 0 95 Chlorinated 66%; P =l,000 75 63. 7 93 Chlorinated 66%; 1,000 87.5 64. 9 99 Chlorinated 64%; 1l=1,300 100 0 64. 0 100 Chlorinated 66%; 1 =1,300 87.5 Chlorinated 68% 12. 5 65. 0 100 Norn. +++=The bank is in very good condition; ++=The bank is in good condition +=Tl1e bank is normal; =The bank is a little hard; =The bank is very hard.

to the chlorine content is 70% from the industrial standpoint. Although the lower limit is, of course, the percentage equal to the chlorine content of the vinyl chloride resin compositions, the appropriate figure to meet the objective of this invention will be 57% for the chlorine content of the resin compositions exclusive of the reinforcing modifier, in view of the relationship between the flow temperature and the Clash and Bergs softening temperature. Details with regard to the resin compositions exclusive of the reinforcing modifier are depicted in FIG. 2. In this graph, the real line and the broken lines 1, 2 and 3 correspond respectively to those shown in FIG. 1.

Composition: Resin Lead stabilizer 5 Metal soaps 1 The following mixture compositions were extruded into sheets:

Composition 1 Parts Composition 2 Parts Composition 3 Parts 63% chlorinated vinyl chloride. 100 66% chlorinated inyl chloride..- 75 66% chlorinated vinyl chloride 75 Lead stabilizer 5 Vinyl chloride (r'=800). 25 Vinyl chloride (P=500).. 25 Metal soaps 2 Lead stabilizer 5 Lead stabilizer 5 2 Metal soaps 2 Metal soaps Blending method: Dry blend method in 75 1. super The mixture compositions of the chlorinated vinyl mixer with stirring for minutes. chloride resins, the vinyl chloride resins and/ or the chlorinated vinyl chloride resins of less than 61% chlorine Metho Of 671 contents and the rubbery butadiene polymers-vinyl com- 55 4 Single screw extruder (L/DZZ, pounds interpolymers showed great improvement in their o 790 mm 4 Wide coat hanggr yp Sheet dle, Screw processing, and moreover, 1n the impact strength, 1m-

-P- provements were evidenced over the chlorinated vinyl chloride resins singly used in which the reinforcing Extruding condition and test results. modifiers were mixed Clash and Load Impact Bergs current Cylinder Die strength softening of the temperatemperaof the temperamotor ture, C. ture, C. Extruding condition sheet ture, 0.

Composition:

1 45A 180-220 210-220 Flow notgood, soon decomposed.. Brittle 95 160-190 185-195 Alittleinitialcoloration,butgood Strong 94 160-185 175-185 Good "do 93 The chlorinated vinyl chloride homopolymers singly The intended products, furthermore, tend to be imused were extruded into sheets with much difficulty, but proved notably in processing when vinyl chloride resins their mixture compositions with the vinyl chloride polyand/ or chlorinated vinyl chloride resins of less than 61% mers were easily extruded into sheets. chlorine content are of low average polymerization de- The compositions of this invention may be subjected to gree, ranging from P=2OO to 800.

the in ection molding and the pressure laminating. 0 EXAMPLE 4 EXA 3 The following mixture compositions were extrusion- The mixture compositions of the chlorinated vinyl molded into sheets. chloride polymers of various polymerization degrees and chlorine contents, the chlorinated vinyl chloride polymers Composition of various polymerization degrees, the chlorinated vinyl Wm chloride polymers of less than 61% chlorine contents an h interpolymers (ABs, MBS, MAB w p to 2233 321 833203 325% 303332i233::' '::::-.?f.-f?l'as"ane ia experiments in many ways. Several examples are listed in :soo vinyl chloride resin 25 25 the following table: F=500 vinyl chloride resin- 25 25 The following compositions were subjected to calenderf gg- 10 in and their bank flow condition was examined. The MABS'L. 15 calender roll used was the 4-roll inverted L calender &i lg gg g g g g g g 5 with the roll diameter 8 inch, the roll temperature 2 180-185 c. u erical figures give parts by weight.

Condition Melt Clash and Impact of the flow Bergs softstrength Chlorinated Reinforcing calender index, ening temkg.-em./ vinyl chlorideresin Parts Vinyl chlorideresin Parts modifier Parts bank C. perature,C. cm.

Chlorinated 63%;T'=1,000- 100 0 183 95 6.7 Chlorinated 63%;T=1,000 10 182 92 16,0 Chlorinated se%;?=1,ooo 0 175 93 7,5 Chlorinated so%;?=1,0o0 1 114 92 Chlorinated e4%;i' =1,aoo 0 189 101 5.3 Chlorinated e4%;1' =1,ao0 20 18a 91 17.0 Chlorinated 66%;=1,300 Chlorinated 58%; 2:800- 0 176 94 7.7 Chlorinated 66%; P=1,300 75 Chlorinated 58%; P=800 25 MABS 10 173 92 20. 5

No'rE.-Diseerrunent oi the condition 0! the calender bank was visually made. The following ranklngsystem is used to describe the results: +++-Very good; -Very hard; Good; -A little hard; +Ordinary. Composition: Lead stabilizer-5 parts; Metal soaps-1 part.

ABS used was the one sold under the trade name of Blending method: Dry blend method in the 75 1. super Blendex 401. MBS was Kane Act B-12, and MABS used mixer with stirring for 10 minutes. was specifically prepared for this purpose. Extrusion h d;

Measurement of the melt flow index was carried out 65 mm Single Screw extruder 22 3 5) by the use of the Kokas flow tester, and the Clash and mm wide coat ban t Sh t Bergs softening temperature and the impact strength 60 g ype ee Screw (Charpy system) were measured in compliance with 118 The extruding condition and the test results:

Clash and B erg Cylinder Die Strength of softening temperatemperathe sheet, temperature, "C. ture, C. Extruding condition kg.-cm./mm.' ture, C.

Composition:

Impact strength measured by falling ball. Ball diamter 1 inch load 1 kg.

With the compositions consisting of the chlorinated between 2 and 800 according to 1 18 (Japanese vinyl chloride resins and the reinforcing modifiers, sheet Industrial Standard)-K6721; and extrusion is very difficult, and, for this reason, proper im- (3) 3 to 30 percent by weight of interpolymer of pact strengths may not be obtained. However, conversion methyl methacrylate-acrylonitrile-butadiene-styrene to the mixture compositions consisting of the chlorinated 5 in the respective proportion of 30 to 10, to 10, vinyl chloride resins, the vinyl chloride resins and the to 50 and to 20. reinforcing modifiers, greatly improved the workability in the sheet extrusion. In this way, improvements were References Cited achieved not only in the appearance of sheets, but also UNITED STATES PATENTS i strellgfh 3,288,886 11/1966 Himei et a1. 260-876 What clamed 3 268 626 8/1966 J t 1 260891 1. Homogeneous blend comprising emimgs e a 3,341,628 9/1967 Bunlng et a1 260--899 (l) 90 to percent by weight of chlorinated vinyl 3 364163 V1968 K 1 260 899 chloride homopolymer or copolymer with comono- 67997 2/1968 q et a f mer polymerizable therewith, with chlorine content 15 mlt 2610 899 of not less than 61% chlorine content; FOREIGN PATENTS (2) 5 to 47 percent by weight of (A) chlorinated vinyl 459,514 7/1935 Great Britain 26o 899 chloride homopolymer or copolymer with comonomer polymerizable therewith, with chlorine content SAMUEL BLECH, Primary Examiner of less than 61% chlorine content, (B) vinyl chloride 20 homopolymer or copolymer with comonomer polym- [13 C1 X11 1 eriza'ble therewith, or (C) mixture thereof, said 2 0. 390

foregoing resins having polymerization degrees of 

